This page is a place to share some ideas, and tricks that you have done to fix or improve your Iltis using parts that were not necessarily intended for the Iltis.
Here is a list of some parts that can be had from your local parts dealer for your Iltis
Replacment spin on type fuel filter Napa Part # 3358 or Fram Part # P7513
Clutch replacment Dynapak part # NU31232, or one used on an 84 Audi 4000 quattro
Fuel pump replacmet part # Carter P61139S -02G26B, Napa also sells a 24V fuel pump that will work
Oil Filter replacmet part #'s Fram PH2870A, Bosch 72150, Mann W719/5
Fan belts gates Part # 7390 (only one belt is needed)
Shocks that are from a CJ5 (spacers needed) will fit Napa part # 738080, Trailmaster 72420 or 57470.
Normal spark plugs and wires can be used in your Iltis by changing your spark plug wire ends, Click here for more information...
Please let me know if you want to add anything to this page
FYI for new Iltis owners your rig shares the same engine that came in the 81-83 VW Rabbit's, the only difference being it's carbureted not fuel injected so the porting on the head is different. Other than that most things on the engine are interchangeable, timing belt, bearings, seals, gaskets, etc.
How To Rebuild Your Trunions
Click here for some tips on rebuilding the Trunion Mounts on your Iltis
Capacitor Replacement
Click here for information on replacing the Capacitor on your Iltis
Add A 12 Volt Charging System
This is a pic of a 12 Volt charging system that I intalled in my Iltis, Click here for more information...
TCI Transistor Fix
Above is a pic of a replacement transistor that I installed in my TCI box (Transistorized Controlled Ignition). Apparently it's common for this transistor to fail, leading to a no spark condition. The replacement is very easy, after you remove the box from the firewall pull the adhesive tape off the back. You will see a brown diamond shape which is some sort of epoxy. The transistor is embedded inside. I chipped away all the epoxy, opened the box, and removed the three wires going to the transistor. One was held on by a screw and the other two were soldered on. That's it, I hooked everything back up that way it was. So far it's working great. The transistor part number I used was MJ10012 at a cost of $7.25 each.
Iltis Master Cylinder
I recently had a conversation with a fellow owner about replacement of the Master Cylinder on his Iltis, here are the details; "It's John again. I found a replacement master cylinder for my Iltis. The parts Source is a 1981 VW with a 1.7L engine, it's master cylinder fits exactly where the Iltis master cylinder goes. The Iltis twin reservoirs do not fit, so you'll need to pick up a reservoir from a junk yard or wherever. The 1.7L reservoir is a press fit versus the Iltis screw in fit. Also, there is one too many holes in the cylinder, so a brass plug needs to be picked up to plug the extra hole. I have driven the Iltis for a week, and it works wonderfully!"
Iltis Rotor Button Swap
It turns out that you can use a rotor button from a 1.7L VW Rabbit on the Iltis engine. The only difference is that the original rotor button that comes on the Iltis has a 6350 RPM governor on it. Unless you plan on revving your engine that high then the stock VW button works great!
Head Light Improvement
I was not happy with the amount of light from the stock headlights so I installed these.... major improvement!
Ignition Conversion
The two pics above are of an ignition switch conversion for my Iltis. As you can see I used the entire ignition switch, wiper/turn signal arm assembly out of a VW Rabbit. This was a very easy conversion as all the plugs and parts are exactly the same. After I removed the assembly from the Iltis I connected the two wires from the old "push button start" to terminal "30 and 15" on the new switch. Everything bolted back in place with a perfect fit. There are two benefits of this conversion, you gain the security of a one only key to start the jeep and also the "steering wheel lock" when the ignition is shut off. This is a very easy project to undertake, total time for the upgrade was under an hour. The total cost depends on how good of a bargain you can get at your local junk yard. The steering wheel is optional, I installed this newer one to spruce up the cockpit a little bit!
C/V Shaft Rebuild
Here is a pic of a C/V drive shaft that I made(top). The stock outer C/V's from an 86 Audi 4000 are the same as the Iltis. The inner C/V's are the same except the spline is different. I picked up a used rear drive shaft from an Audi 4000, it was a little bit to long, so I cut it, machined a pin, (the Audi shaft is hollow hence the need for a pin), pressed the shaft back together, and welded it. Total cost.... about $20!
If you have any tricks to share please e-mail me and I will post them.
iltisvw@hotmail
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